Sweatband material and headwear piece incorporating the sweatband material

ABSTRACT

An elongate sweatband material for incorporation into a headwear piece and having a length. Thread is knitted to define interengaged U-shaped loops that: a) have a width that is enlarged to permit elongation of the sweatband in a lengthwise direction a first amount under a tensile force of a first magnitude applied in a direction parallel to the length of the sweatband material; and b) cooperate to reinforce each other in a direction transversely to the lengthwise direction so that the sweatband stretches transversely to the lengthwise direction a second amount that is substantially less than the first amount under a tensile force of the first magnitude applied in a direction transversely to the length of the sweatband material.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to sweatbands, as used on headwear and, more particularly, to a sweatband material that is more stretchable in a circumferential direction around a wearer's head than in a direction transversely thereto.

2. Background Art

Sweatbands are incorporated into a multitude of different types of headwear. Regardless of its precise configuration, headwear has an inside region that embraces a wearer's head by extending either fully or partially therearound: A sweatband is applied at this inside region to directly engage the wearer's head where it is embraced by the headwear.

One of the most popular types of headwear, and that which is sold in the highest volume worldwide, is the baseball-style cap. A typical baseball-style cap consists of an inverted, cup-shaped crown bounding an opening into which a wearer's head is directed. A rim/bill projects angularly away from the crown at a forward region thereof.

Because the demand for this type of headwear piece spans all age groups, accommodation over a wide range of head sizes is required. One manner of meeting demand is to offer each individual headwear piece style in all different sizes, whereby there is a “custom fit”. Manufacturing and inventorying such a wide range of sizes is impractical, from both the standpoints of manufacturing and inventory control. At the manufacturing end, the separate sizes must be separately constructed and segregated for separate shipping. Those wishing to offer these custom headwear pieces must keep on hand inventories based upon anticipated demand for each size. Keeping on hand volumes of each size requires a significant amount of storage space. Since the anticipation of demand is not a science, inevitably purveyors will be faced with shortages of certain sizes and excesses of other sizes.

The above problems led to the development of size adjustable baseball-style caps. In one basic form, a cutout is provided at the rear of the crown. Connectable strap parts are attached, one each to spaced edges of the cutout. By strategically connecting the strap parts, the effective overall length of the strap is varied, which in turn varies the circumference of the crown. This construction has the drawback that it may produce a wrinkled crown configuration. Additionally, there may be an uncomfortable localized pressure applied to the wearer's head at the region of the strap.

To eliminate the above problems, the industry has developed a large number of different designs that allow the fabric on the crown to stretch to accommodate different head sizes. These caps are commonly referred to in the industry as “free size” caps. The material of the crown may be stretchable at selected locations or fully around the circumference thereof. To accommodate this construction, the sweatbands, that are incorporated into the inside region of the crowns, must be made to stretch substantially in unison with the crown material.

Various sweatband constructions have been devised. In one form, the sweatband material is made to be universally stretchable.

More commonly, for higher end products in which an unwrinkled and fitted appearance is desired, the sweatband material has been made to expand uniaxially principally in a circumferential direction, with limited transverse/vertical elongation capability. These designs have commonly been made using threads that are knitted and/or woven to produce this capability.

Common to these designs is the incorporation of different threads to make up the warp and weft to provide the desired stretching characteristics. For example, it is common to incorporate stretchable spandex thread or stretchable rubber thread in at least the weft threads that extend circumferentially.

One drawback with the prior constructions is that they require the use of different thread compositions through which the stretching characteristics of the warp and weft can be made different. This is inconvenient from the standpoint of coordinating the ordering and handling of separate threads during the manufacturing process.

Additionally, those threads that are elastic/extendible in a lengthwise direction under tensile forces are generally more expensive than threads, such as those made from polyester, that have little lengthwise extensibility under tensile loading.

Still further, threads that are elastic in nature may have compromised elastic properties over time and/or when exposed to certain environmental conditions, such as heat, chemicals, etc.

While the headwear industry has devised headwear that effectively makes possible a single construction that will accommodate a range of head sizes, the above-noted problems persist. The industry continues to search out viable alternative constructions that improve on existing designs.

SUMMARY OF THE INVENTION

In one form, the invention is directed to an elongate sweatband material for incorporation into a headwear piece. The elongate sweatband material has a length and includes thread knitted to define interengaged U-shaped loops that: a) have a width that is enlarged to permit elongation of the sweatband material in a lengthwise direction a first amount under a tensile force of a first magnitude applied in a direction parallel to the length of the sweatband material; and b) cooperate to reinforce each other in a direction transversely to the lengthwise direction so that the sweatband material stretches transversely to the lengthwise direction a second amount that is substantially less than the first amount under a tensile force of the first magnitude applied in a direction transversely to the length of the sweatband material.

In one form, the U-shaped loops are reconfigured under a tensile force applied parallel to the length of the sweatband material primarily by repositioning of the thread without any significant elongation of the thread.

In one form, the sweatband material is elongated under a tensile force applied parallel to the length of the sweatband material primarily by widening of the U-shaped loops without any significant elongation of the thread defining the U-shaped loops.

In one form, the sweatband material is made substantially entirely from thread of a single composition.

In one form, the U-shaped loops are made from polyester thread.

In one form, the sweatband material is made substantially entirely from polyester thread.

In one form, the polyester thread has a composition that is the same throughout substantially the entire sweatband material.

In one form, the elongate sweatband material is provided in combination with a headwear piece having an inside region that embraces a wearer's head with the headwear piece in an operative position. The elongate sweatband material is applied to the headwear piece to reside at the inside region and against a wearer's head.

In one form, the headwear piece has a crown that extends continuously around a wearer's head and the elongate sweatband material extends continuously around the crown at the inside region.

In one form, the headwear piece is a baseball-style cap with a crown and a rim/bill projecting from the crown and the elongate sweatband material is applied at the inside region of the crown.

In one form, the elongate sweatband material has a width and spaced widthwise edges and the elongate sweatband material is sewn to the headwear piece along one of the spaced edges.

In one form, the headwear piece has a crown and the elongate sweatband material extends through 360° around the crown at the inside region.

In one form, a line of stitching is formed at the other of the spaced edges.

In one form, the other of the spaced edges is not connected directly to the headwear piece.

The invention is further directed to an elongate sweatband material for incorporation into a headwear piece, in which the elongate sweatband material has a length and width and includes a thread of a first composition that is knitted to extend in both lengthwise and widthwise directions to: a) permit elongation of the sweatband material in a lengthwise direction a first amount under a tensile force of a first magnitude applied in a lengthwise direction; and b) limit elongation of the sweatband material in a widthwise direction to an amount that is substantially less than the first amount under a tensile force of the first magnitude applied in a widthwise direction.

In one form, the sweatband material is made substantially entirely from the thread of the first composition.

In one form, the elongation of the sweatband material in the lengthwise direction under an applied tensile force results primarily from repositioning of the thread without any significant elongation of the thread.

In one form, the sweatband material is provided in combination with a headwear piece having an inside region that embraces a wearer's head with the headwear piece in an operative position. The elongate sweatband material is applied to the headwear piece to reside at the inside region and against a wearer's head.

In one form, the headwear piece has a crown that extends continuously around a wearer's head and the elongate sweatband material extends continuously around the crown at the inside region.

In one form, the headwear piece is a baseball-style cap with a crown and a rim/bill projecting from the crown and the elongate sweatband material is applied at the inside region of the crown.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a headwear piece made according to the invention;

FIG. 2 is a perspective view of a headwear piece, as shown in FIG. 1, in the form of a visor;

FIG. 3 is a perspective view of a headwear piece, as shown in FIG. 1, in the form of a baseball-style cap;

FIG. 4 is a view of the cap in FIG. 3 from a different perspective;

FIG. 5 is a bottom view of the cap in FIGS. 3 and 4 in partially schematic form;

FIG. 6 is a bottom view of the cap in FIGS. 3-5;

FIG. 7 is a cross-sectional view of a connection between adjacent gores and a backing tape taken along line 7-7 of FIG. 6;

FIG. 8 is a cross-sectional view of a connection between adjacent gores and a backing tape taken along line 8-8 of FIG. 6;

FIG. 9 is an elevation view of a strip used to form the inventive sweatband;

FIG. 10 is a plan view of the strip in FIG. 9 sewn to define a continuous shape;

FIG. 11 is an enlarged, elevation view of a portion of the inventive sweatband and showing knitted thread thereon with the sweatband in a relaxed state;

FIG. 12 is a view corresponding to that in FIG. 11 with a circumferential tensile force applied to the sweatband;

FIG. 13 is a cross-sectional view of a connection between the sweatband and crown taken along line 13-13 of FIG. 4; and

FIG. 14 is a perspective view of a modified form of sweatband, according to the invention, formed as a single, continuous layer.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring initially to FIG. 1, a headwear piece, according to the present invention, is shown at 10. The headwear piece 10 is shown in schematic form since it is contemplated that the basic components therein might vary considerably from those in the specific embodiments described hereinbelow. The invention encompasses those variations.

The headwear piece 10 consists of a crown 12 defined by a plurality of gores 14 that cooperatively produce a receptacle into which a user's head can be directed to place the headwear piece 10 in an operative position thereon. A sweatband 16 on the crown 12 engages a wearer's head with the headwear piece in the operative position. In the schematic form, no rim/bill is depicted since the invention can be practiced without such a structure.

The crown 12 may have a closed top or may be open; the latter being a construction typical of a headwear piece in the form of a visor 18, as shown in FIG. 2. The inventive concept could be practiced with the visor 18 in substantially the same manner as described hereinbelow for the headwear piece 10, shown in FIGS. 3-13. While the crown 12 may extend continuously around a wearer's head in the operative position therefor, as it does in FIGS. 3-13, the visor 18 is shown with a crown 20 that is interrupted at the back portion 22 thereof.

Referring now to FIGS. 3-13, one preferred form of headwear piece 10, according to the invention, is depicted. The headwear piece 10 in these figures is a baseball-style cap. The headwear piece 10 has, in this particular embodiment, six triangularly-shaped gores 14 a,14 b,14 c,14 d, 14 e,14 f that are joined at connecting lines 24,26,28,30,32,34 at spaced circumferential locations to cooperatively produce an inverted, cup-shaped receptacle 36 into which a user's head can be directed with the headwear piece 10 in an operative position. The bottom portion 38 of the crown 12 extends fully around, and embraces, a wearer's head to maintain the headwear piece 10 securely in the operative position therefor.

The present invention is concerned primarily with the construction of the sweatband 16, and its incorporation into the headwear piece 12, as described in greater detail hereinbelow. The sweatband 16 resides at an inside region of the crown 12 and, more specifically, against the inside surface 40 of the crown 12 bounding the receptacle 36 at the bottom portion 38 of the crown 12. The sweatband 16 has a length L and a width W, with the former extending circumferentially and the latter transversely thereto in a vertical direction. A line of stitching 42 secures a bottom edge 44 of the sweatband 16 at a bottom edge 46 of the crown 12. Through this arrangement, the sweatband 16 can be folded into and out of the receptacle 36 around the stitching line 42. The sweatband 16 could, however, be secured to the gores 14 a-14 f to be at all times maintained against the inside surface 40 bounding the receptacle 36.

In this embodiment, a rim/bill 50 is attached to the crown 12 at a forward portion 52 thereon and projects in a forward direction.

According to the invention, the gores 14 a,14 b,14 c,14 d are made from either universally stretchable material or uniaxially stretchable material that is oriented on the gores 14 a,14 b,14 c,14 d so that they are each stretchable circumferentially, as indicated by the arrows 56,58,60,62, thereby to increase the effective diameter D of the receptacle 36 defined by the crown 20, while not being stretchable in a transverse, generally vertical, direction.

A backing/seam tape 66 is applied to the inside surface 40 of the crown 20 to overlie the region of the connecting lines 28,34. The backing tape 66 is attached to the surface 40 through spaced lines of stitching 68,70, shown equidistantly spaced from the connecting lines 28,34 at circumferentially spaced locations. The backing tape 66 is made from a non-stretchable material, or at least one that does not stretch appreciably in a circumferential direction.

It should be understood that the distinction between “stretchable” and “non-stretchable” relates to a degree of stretching capability. Virtually every material contemplated for use will have a certain ability to stretch under a tensile force. However, it is contemplated that in response to the circumferential forces generated by a user's pressing his/her head, of at least a predetermined effective diameter, into the receptacle 36, the exemplary gores 14 c,14 d will circumferentially stretch away from the connecting line 28, and more particularly the lines of stitching 68,70. By attaching the backing tape 66, the gores 14 c,14 d become non-stretchable in a circumferential direction over a width W1 between the lines of stitching 68,70 at the location where the backing tape 66 overlies these gores 14 c,14 d.

Similar lengths of backing tape 66 a,66 b respectively overlie the connecting lines 26,32 and 24,30. They function in the same manner between the gores 14 b,14 c and 14 a,14 b, respectively.

The crown 12 is designed to stretch, thereby to increase the effective diameter D of the receptacle 36 in response to the direction of a user's head, of at least the aforementioned predetermined effective diameter, into the receptacle 36. As this occurs, the gores 14 a,14 b,14 c,14 d simultaneously stretch circumferentially to effectively enlarge the diameter D. As this occurs, the gore 14 d stretches circumferentially away from the connecting line 28 and, more particularly, the line of stitching 70, while the gore 14 c stretches circumferentially oppositely away from the connecting line 28 and, more particularly, the line of stitching 68. The gores 14 b,14 c stretch in the same manner away from the connecting line 26 and corresponding lines of stitching 68′,70′. Likewise, the gores 14 a,14 b stretch away from the connecting line 24 and the lines of stitching 68″,70″.

While the gores 14 e,14 f could be made from a stretchable material, more preferably the material thereof is circumferentially nonstretchable. That is because each of these gores 14 e,14 f is connected to the rim/bill 50 that is substantially non-stretchable in a circumferential direction. Accordingly, while on one half of the crown 12 the gore 14 a is stretchable circumferentially away from the connecting line 34, and more specifically from the line of stitching 68, and the gore 14 b is circumferentially stretchable away from the connecting line 24, and the line of stitching 70″, the gores 14 e,14 f remain substantially fixed in circumferential dimension.

While not shown, the sweatband 16 may have a segment at 92, circumferentially corresponding to the dimension of the rim/bill 50 between the ends 96,98, that is non-stretchable in a circumferential direction. In one preferred form, as set forth below, the sweatband 16 has the same construction throughout its length and extends through 360° around the crown 12 and a wearer's head.

As noted above, the gores 14 a-14 f may be made to be uniaxially stretchable in a circumferential direction or may alternatively be universally stretchable. The former is preferred. As one example, the gores 14 a-14 f may be made from fabric that is single woven with polyurethane or spun yarn as the weft to provide the circumferential stretching capability. Weft yarns, that are covered with polyurethane or spandex, are known and usable for the crown fabric.

The backing tape can likewise be made from a non-stretchable fabric.

There is no particular limitation as to how the individual gores 14 a-14 d are formed or connected. In one exemplary form, the gores 14 a,14 b,14 c,14 d are connected to each other in the same manner as shown at the connecting line 28 in FIG. 7. The gore 14 c has a main body 104 and an under-folded portion 106. The gore 14 d has a main body 108 and an under-folded portion 110. A line of stitching 112 connects the gores 14 c,14 d by uniting abutted edges between the bodies 104, 108 and under-folded portions 106, 110. The line of stitching 68 extends through the body 104, under-folded portion 106 and backing tape 66, with the line of stitching 70 extending through the body 108, under-folded portion 110 and backing tape 66.

The gores 14 a,14 f and 14 d,14 e are joined at their respective connecting lines 34, 30 in the same manner, as seen most clearly in FIG. 8. At the exemplary connecting line 30, between the gores 14 d,14 e, the gore 14 d has an under-folded portion 114. The under-folded portion 114 overlies the gore 14 e under which the backing tape 66 b is located. The line of stitching 68″ extends through and unites a main body 116 of the gore 14 d, the under-folded portion 114, the gore 14 e and the backing tape 66 b. The line of stitching 70″ extends through the gore 14 e and backing tape 66 b.

Again, it should be noted that this is just one preferred method of connecting the gores 14 a-14 f. Virtually any type of structure that joins the gores 14 a-14 f is contemplated, among which is an adhesive bonding of components. It is conceivable that a tape could be used to maintain the gores 14 a-14 f together without otherwise directly stitching the gores 14 a-14 f, one to the other.

In one preferred form, the sweatband 16 is made in the form of a strip 120 with a length L and width W. The ends 122, 124 of the strip 120 are folded against each other as shown in FIG. 10 and connected thereat through one or more lines of stitching 126 to produce an endless ring shape that extends through 360°.

Alternatively, as shown in FIG. 14, a modified form of sweatband 16′ can be made as one continuous ring layer 128.

The strip 120 is joined to the crown 12 as shown in FIG. 13. The bottom end 130 of the crown is folded upwardly to produce stacked layers L, L1. The two layers L, L1 are joined to the bottom of the sweatband 16 through the aforementioned line of stitching 42. The line of stitching 42 is formed adjacent to the bottom, widthwise edge 132 of the sweatband 16. A corresponding line of stitching 134 may be provided adjacent the opposite widthwise edge 136. The line of stitching 134 may be provided to maintain a knitted thread pattern, as hereinafter described, or may be alternatively additionally extended through the crown 12, in the event that it is desired that the sweatband 16 be secured against folding outwardly, as previously described.

The sweatband 16 is made from thread 138 that is knitted as shown particularly in FIGS. 11 and 12. More particularly, the thread is knitted to define interengaged U-shaped loops 140 opening in one vertical direction and loops 140′ opening vertically oppositely thereto. The loops 140, 140′ have a relaxed width LW that is enlarged to a width LW1 to permit elongation of the sweatband material in a lengthwise direction a first amount under a tensile force of a first magnitude applied in a direction parallel to the length of the sweatband material. The U-shaped loops 140, 140′ cooperate to reinforce each other in a widthwise direction, transversely to the lengthwise direction, so that the sweatband material stretches transversely to the lengthwise direction a second amount, that is substantially less than the first amount, under a tensile force of the first magnitude applied in a direction transversely to the length of the sweatband material. Under this tensile force, the U-shaped loops 140, 140′ are reconfigured primarily by repositioning of the thread 138 to produce the widened configuration shown in FIG. 12, without requiring any significant elongation of the thread 138.

While the thread 138 could be made from a material that elongates significantly under a tensile force, the inventive construction allows the use of thread 138 that is substantially inextensible under a tensile force to produce a sweatband 16 that is uniaxially extensible in a circumferential direction. As an example, polyester thread is in the category of thread that is not considered to be significantly extensible. It is possible to make the entire sweatband 16 from a single thread composition, such as polyester, to provide the uniaxial stretching capability that has heretofore been made possible by the use of different thread compositions in warp and weft components.

The invention contemplates that other threads and other components could be incorporated into the knitted construction shown in FIGS. 11 and 12. However, it is preferred that the primary stretching capability be afforded by the single type of thread that is, in a preferred form, substantially inextensible, as is polyester.

In the specific form shown, the loops 140 are shown in multiple rows, with three such rows R1, R2, R3 shown in FIGS. 11 and 12. Each row R1, R2, R3 consists of thread 138 formed to define alternating loops 140, 140′ opening in opposite directions. The loops 140 in the row R2, adjacent to the row R1, are intermeshed by causing the loops 140 in the row R2 each to wrap around a loop 140 at a coinciding lengthwise location in the row R1. This pattern is repeated throughout the entire width of the sweatband 16.

The precise knitting pattern could vary from that shown in FIGS. 11 and 12. What is contemplated is that a thread of a single composition can be knitted to extend in both lengthwise and widthwise directions to: a) permit elongation of the sweatband material in a lengthwise direction a first amount under a tensile force of a first magnitude applied in a lengthwise direction; and b) limit elongation of the sweatband material in a widthwise direction to an amount that is substantially less than the first amount under a tensile force of the first magnitude applied in a widthwise direction. That is, the invention contemplates that there be uniaxial stretching capability by reason of repositioning of the thread without any significant elongation thereof.

Of course, the thread 138 could be made from an extensible material and knitted as described herein consistent with the inventive concepts.

The foregoing disclosure of specific embodiments is intended to be illustrative of the broad concepts comprehended by the invention. 

1. An elongate sweatband material for incorporation into a headwear piece, the elongate sweatband material having a length and comprising: thread knitted to define interengaged U-shaped loops that: a) have a width that is enlarged to permit elongation of the sweatband material in a lengthwise direction a first amount under a tensile force of a first magnitude applied in a direction parallel to the length of the sweatband material; and b) cooperate to reinforce each other in a direction transversely to the lengthwise direction so that the sweatband material stretches transversely to the lengthwise direction a second amount that is substantially less than the first amount under a tensile force of the first magnitude applied in a direction transversely to the length of the sweatband material.
 2. The elongate sweatband material according to claim 1 wherein the U-shaped loops are reconfigured under a tensile force applied parallel to the length of the sweatband material primarily by repositioning of the thread without any significant elongation of the thread.
 3. The elongate sweatband material according to claim 1 wherein the sweatband material is elongated under a tensile force applied parallel to the length of the sweatband material primarily by widening of the U-shaped loops without any significant elongation of the thread defining the U-shaped loops.
 4. The elongate sweatband material according to claim 1 wherein the sweatband material is made substantially entirely from thread of a single composition.
 5. The elongate sweatband material according to claim 1 wherein the U-shaped loops are made from polyester thread.
 6. The elongate sweatband material according to claim 1 wherein the sweatband material is made substantially entirely from polyester thread.
 7. The elongate sweatband material according to claim 6 wherein the polyester thread has a composition that is the same throughout substantially the entire sweatband material.
 8. The elongate sweatband material in combination with a headwear piece having an inside region that embraces a wearer's head with the headwear piece in an operative position, and the elongate sweatband material is applied to the headwear piece to reside at the inside region and against a wearer's head.
 9. The elongate sweatband material according to claim 8 wherein the headwear piece has a crown that extends continuously around a wearer's head and the elongate sweatband material extends continuously around the crown at the inside region.
 10. The elongate sweatband material according to claim 8 wherein the headwear piece comprises a baseball-style cap with a crown and a rim/bill projecting from the crown and the elongate sweatband material is applied at the inside region on the crown.
 11. The elongate sweatband material according to claim 8 wherein the elongate sweatband material has a width and spaced widthwise edges and the elongate sweatband material is sewn to the headwear piece along one of the spaced edges.
 12. The elongate sweatband material according to claim 11 wherein the headwear piece has a crown and the elongate sweatband material extends through 360° around the crown at the inside region.
 13. The elongate sweatband material according to claim 11 wherein a line of stitching is formed at the other of the spaced edges.
 14. The elongate sweatband material according to claim 13 wherein the other of the spaced edges is not connected directly to the headwear piece.
 15. An elongate sweatband material for incorporation into a headwear piece, the elongate sweatband material having a length and width and comprising: a thread of a first composition that is knitted to extend in both lengthwise and widthwise directions to: a) permit elongation of the sweatband material in a lengthwise direction a first amount under a tensile force of a first magnitude applied in a lengthwise direction; and b) limit elongation of the sweatband material in a widthwise direction to an amount that is substantially less than the first amount under a tensile force of the first magnitude applied in a widthwise direction.
 16. The elongate sweatband material according to claim 15 wherein the sweatband material is made substantially entirely from the thread of the first composition.
 17. The elongate sweatband material according to claim 15 wherein the elongation of the sweatband material in the lengthwise direction under an applied tensile force results primarily from repositioning of the thread without any significant elongation of the thread.
 18. The elongate sweatband material according to claim 15 in combination with a headwear piece having an inside region that embraces a wearer's head with the headwear piece in an operative position, and the elongate sweatband material is applied to the headwear piece to reside at the inside region and against a wearer's head.
 19. The elongate sweatband material according to claim 18 wherein the headwear piece has a crown that extends continuously around a wearer's head and the elongate sweatband material extends continuously around the crown at the inside region.
 20. The elongate sweatband material according to claim 18 wherein the headwear piece comprises a baseball-style cap with a crown and a rim/bill projecting from the crown and the elongate sweatband material is applied at the inside region on the crown. 